Reinforced skateboard deck

ABSTRACT

A reinforced skateboard deck providing a rupture resistant region and a protective region to inhibit degradation of the rupture resistant region during use is disclosed herein.

This is a continuation application of U.S. Ser. No. 13/342,799, now U.S.Pat. No. 8,419,026, filed on Jan. 3, 2012, which is a continuation ofU.S. Ser. No. 12/830,298, now U.S. Pat. No. 8,087,681, filed on Jul. 3,2010, which is a continuation of U.S. Ser. No. 11/940,233, now U.S. Pat.No. 7,748,725, filed on Nov. 14, 2007, all of which are entitledReinforced Skateboard Deck and hereby incorporated by reference in theirentireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of skateboard decks, and morespecifically, to skateboard decks incorporating destructive forceresistant materials.

2. Background

Skateboards are typically used today to ride up, over, and off of rampsand other structures, and the skateboard deck undergoes considerablestress when the rider and skateboard return to the ground. Skateboarddecks have been strengthened by a laminated structure typically aseven-ply hardwood with the grain direction of the plies varied toprovide strengthening in more than one direction. Such laminate decksare still subject to failure under significant impacts during typicalskateboarding use. It is believed that a common failure of the laminatedeck occurs where the top layer of the laminate will fail in tensionwhen loaded, then the second sub-layer below that will in turn fail intension, and then the next and next, working from the top of the deck tothe bottom surface.

Skateboard decks have also been provided with fiber reinforcement,typically a fiberglass and resin matrix such as epoxy or otherthermosetting resin. Fiber reinforced skateboards are known in the art,with some designs placing the fiber reinforcement between the hardwoodveneer layers, while other designs have the fiber on the bottom or topmajor surface of the skateboard. It is believed that the location wherea fiber reinforcement has the greatest effect in strengthening againstcommon failure-inducing loads is the top major surface of theskateboard. When fiber reinforcement is placed in such a way as to befirmly and permanently adhered to the top major surface of theskateboard, the common failure mode is prevented from initiating. Thisis believed to be because the tensile load is distributed over not onlythe laminate structure of hardwood veneers, but also by augmenting thestrength of the laminate structure by the fiber and resin matrixreinforcement. Propagation of rupture of the laminated hardwood veneersis believed to be reduced, because the fibers are both adding stiffnessto the structure, and adding overall tensile strength to the skateboard.

Providing a layer of fiber reinforcement over the entire major surfacesof the skateboard deck has practical drawbacks given the common natureof use of skateboards where the edges of the deck are worn away bycontact with the ground. The result of such contact and wearing away isthat fibers are exposed at the edge of the deck. These exposed fibers,particularly in the case of glass or carbon fiber can be rigid andsharp. In the case of other fibers, such as aramid, or para-aramids orother engineering thermoplastic fibers, the exposed fibers are typicallysoft and pliable, but in any case create a cosmetically unattractiveedge.

Therefore, what is needed and heretofore unavailable is a reinforcedskateboard deck constructed to resist destructive forces typicallyoccurring during use while protecting the reinforcing elements from wearand tear.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment constructed in accordance withthe principles of the present invention, a multi-layer board with anintermediate section having a pair of opposing lateral edge sidewallsbetween a tail section and a nose section and an undersurfaceconstructed to receive at least one set of trucks may include a ruptureresistant layer extending at least partially through the intermediatesection with a first region and a second region of the rupture resistantlayer cooperating to form at least a portion of a dual density, exposed,foot bearing surface, with the first region including a fiber-reinforcedmaterial having a pair of outermost lateral edges spaced interior to theopposing lateral edge sidewalls of the intermediate section to form arecess at least partially occupied by the second region to define afirst region protective barrier to prevent wear of the first region whenthe board slides along at least one of the opposing lateral edgesidewalls in use.

In another aspect of the present invention, the reinforced regionincludes a spacer layer.

In yet another aspect of the present invention, the reinforced regionand the protective side barrier form complementary portions of theexposed foot bearing surface.

Methods for constructing a reinforced skateboard deck are disclosed aswell.

Other aspects of the present invention will become apparent with furtherreference to the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the layers of a skateboard deck inaccordance with an embodiment of the present description, showing anupper layer formed of a fiber-reinforced layer inlaid within a veneer,and six additional layers, with varying strand orientations, preparedfor assembly;

FIG. 2 is a top plan view of the veneer for the upper layer prior to aninitial cutting, showing a typical dimension;

FIG. 3 is a top plan view of the veneer of FIG. 2 with a central portionremoved to provide a side barrier defining a central opening;

FIG. 4 is a top plan view of the fiber-reinforced layer for the upperlayer, showing a typical dimension, prior to an initial cutting;

FIG. 5 is a top plan view of the fiber-reinforced layer, after cuttingto a typical shape, to fit the layer into the central opening of theside barrier;

FIG. 6 is a top plan view of the fiber-reinforced layer and the sidebarrier assembled to provide the upper layer;

FIG. 7 is a perspective view of a removable adhesive tape being appliedto the fiber-reinforced layer and the side barrier to hold themtogether;

FIG. 8 is an end elevation view of the layers arranged together,including a spacer layer beneath the fiber-reinforced layer, showing atypical dimension;

FIG. 9 is an end elevation view of a mold pressing the layers togetherto form a blank skateboard deck which may subsequently be cut to adesired size and shape; and

FIG. 10 is a perspective view of a skateboard deck press molded toprovide a raised nose and tail and cut to a final desired shape.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, a skateboard deck, indicated generally at 10, istypically formed of a series of wood veneer layers 12, which are stackedand assembled together. Alternatively, other suitable materials, such asthermoplastics, and non-layered constructions may be used.

An upper layer 14 provides a top surface 16 and a bottom surface 18. Thetop surface is typically the top structural (riding or foot bearing)surface of the skateboard deck, although a grip tape or other similarlayer may be applied over the top surface. Upper layer 14 includes aninlaid, fiber-reinforced layer 20 that provides a portion of top surface16.

Fiber-reinforced layer 20 is typically formed substantially of wovenpara-aramid fibers. The fiber-reinforced layer may be made withunidirectional or bi-directional para-aramid fibers loosely woven into afabric. As an example, layer 20 may include Kevlar® RTM (resin transfermolded) fabric encased in an adhesive matrix. As an example, the Kevlar®fabric may be substantially saturated with polyurethane, which is thenallowed to harden before further processing. Other components of theadhesive matrix would include a resin of epoxy or polyvinyl.

Fiber-reinforced layer 20 defines an edge 22 (see also FIG. 5), andtypically has an oval or racetrack shape, although other shapes may beused as desirable for a particular skateboard design.

Upper layer 14 typically includes a side barrier 24 that also provides aportion of top surface 16. Preferably, the side barrier and thefiber-reinforced layer together provide the entire top surface butalternatively other structure may provide a part of the top surface.Also preferably, the side barrier extends around the entire edge of thefiber-reinforced layer. Alternatively, the side barrier extends aroundonly a portion of the edge of the fiber-reinforced layer, in which casesome other structure may run alongside a portion of the fiber-reinforcedlayer or no structure as suitable to the desired skateboard design. Theside barrier is typically a wood veneer, and as such includes thefibrous material that is naturally found in wood, however, the sidebarrier typically does not include any fiber reinforcement such as toleave behind a fringe or sharp edge of fibers as may be the case withKevlar® or glass or carbon fibers. Alternatively, side barrier 24 may beformed from a thermoplastic sheet.

As best seen in FIGS. 2 and 3, side barrier 24 is made by starting witha wood veneer blank 26 from which a central portion 28 is removed toprovide a central opening 30, typically in an oval or racetrack shape,but alternatively with any shape suited to the specific skateboard.Thus, central opening 30 is defined by side barrier 24.

As best seen in FIGS. 4 and 5, fiber-reinforced layer 20 is made bystarting with a sheet of woven Kevlar® fabric 32 encased in an adhesivematrix, such as by substantial saturation with polyurethane. Sheet 32 iscut into an oval racetrack, or other suitable shape to produce layer 20,which is preferably closely fitted for central opening 30 of sidebarrier 24 (see FIG. 6).

Side barrier 24 and fiber-reinforced layer 20 are preferably die cutfrom blank 26 and sheet 32, respectively, but any suitable means may beused. With die-cutting, the same press and die may be used to cut boththe blank and the sheet. Side barrier 24 and fiber-reinforced layer 20are typically of equal thickness although some variation is permitted.Alternatively, the fiber-reinforced layer may be substantially thinner,with the difference made up by a spacer layer 34 (see FIGS. 8 and 9),typically of the same shape, such as oval, as fiber-reinforced layer 20.Spacer layer 34 may be affixed, e.g., by adhesive, to the bottom surfaceof fiber-reinforced layer 20, and may be cut to shape either separatelyor together with the fiber-reinforced layer.

As shown in FIGS. 6 and 7, after fiber-reinforced layer 20 and sidebarrier 24 are combined by placing layer 20 within central opening 30,they may be temporarily held together by application of an adhesive tape36, e.g., the Peel A Play tape made by the R Tape Corporation of NewJersey. Adhesive tape 36 may be applied by a heat transfer press.

As best seen in FIGS. 1, 8, and 9, skateboard deck 10 may include afirst lower layer 38, typically a wood veneer, defining an upper surface40 and a lower surface 42. Upper layer 14, comprising side barrier 24and fiber-reinforced layer 20, is affixed, typically by application ofadhesive and subsequent press molding at suitable heat and temperature,to first lower layer 38. Additional lower layers may be included asdesired in consideration of desired weight and strength factors. Forexample, second, third, fourth, fifth, sixth, and seventh lower layers44, with ultimate bottom surface 46, may be affixed successively beneaththe first lower layer, typically by application of adhesive andsubsequent press molding at suitable heat and temperature.

Typically the lower layers are wood or other structural material with astrand orientation that is varied from layer to layer. As an example,with seven lower layers, two may be oriented to provide maximum crossboard strength, while the remaining five maximize along board strength,although this scheme will be varied as appropriate for the desiredperformance characteristics.

FIGS. 1, 8, and, 9 also illustrate that fiber-reinforced layer 20 isinlaid within side barrier 14, and side barrier 14 preferably surroundssubstantially all of edge 22 of fiber-reinforced layer 20. As shown inFIG. 10, skateboard deck 10 may be press-molded to provide a raised tail48 and a raised nose 50 and cut to a final desired shape. Furthermore,deck 10 may be drilled for truck mounting holes, and then trucks,bearing and wheels may be mounted to provide a skateboard ready forriding. A grip tape or other suitable tape, stickers or the like may beaffixed over the top surface. Preferably the upper surface offiber-reinforced layer 20 and the upper surface of side barrier 24 areflush with one another, presenting a smooth transition with no visiblestep.

Alternatively, upper layer 14 may be formed substantially of an adhesivematrix including a central portion of woven fiber encased therein toprovide the fiber-reinforced layer. In this embodiment, the adhesivematrix includes an outer portion without woven fiber to provide the sidebarrier.

As described herein, skateboard deck 10 includes a top (or foot bearing)surface 16 for the rider's feet, and a bottom surface 46 for theconnection of trucks and wheels. The top surface is provided in part bya fiber-reinforced layer 20. The top surface is further provided by aside barrier 24 extending around at least a portion of thefiber-reinforced layer.

Typical thicknesses for the fiber-reinforced layer after saturation withpolyurethanes are between about 0.010 to about 0.050-inches. Typicalthicknesses for side barrier 14 are between about 0.040 to about0.065-inches. The thickness of spacer layer 34 typically is adjusted tothe appropriate thickness to accommodate the difference betweenfiber-reinforced layer 20 and side barrier 24 and provide a flush topsurface 16. As an example, where side barrier 14 is 0.060-inches thick,and fiber-reinforced layer 20 is 0.020-includes thick, spacer layer 14is preferably 0.040-inches in thickness. All of these dimensions may bevaried within and beyond these ranges as suited to the particularskateboard design.

Side barrier 14 may have varying width dimensions relative to skateboarddeck 10 and fiber-reinforced layer 20. The dimensions of the sidebarrier may be substantially uniform around the edge of the skateboard,or they may vary significantly as desired for specific skateboardcharacteristics. For example, the side barrier may be narrower along thesides as compared to the nose and tail. Side barrier 14 preferably has aminimum width of 0.125-inches along each long side of the skateboard.Side barrier 14 preferably has a width dimension between about0.125-inches and about 6-inches adjacent the nose and tail of theskateboard. All of these dimensions may, be varied within and beyondthese ranges as suited to the particular skateboard design. With thisdesign, fiber-reinforced layer 20 is inset away from the edge of theskateboard, so that the fibers are shielded from contact when theskateboard edges are scraped on the ground or other surface.Fiber-reinforced layer 20 is preferably inlaid on top surface 16 of deck10, and additionally or alternatively may be inlaid on lower surface 42.

It will be appreciated that the incorporation of the fiber-reinforcedlayer 20 and/or the fiber-reinforced layer as bonded to another layer ofthe deck assists in significantly resisting tensile forces commonlyassociated with use and improves the overall rupture resistance of thedeck. When used at or near the top layer as a part thereof, theeffectiveness of this rupture resistance feature increases.

While the present invention has been described herein in terms of anumber of preferred embodiments for skateboard decks, various changesand improvements may also be made to the invention without departingfrom the scope thereof. The subject matter described herein includes allnovel and non-obvious combinations and subcombinations of the variouselements, features, functions and/or properties disclosed herein.Similarly, where the claims recite “a” or “a first” element or theequivalent thereof, such claims should be understood to includeincorporation of one or more such elements, neither requiring norexcluding two or more such elements.

What is claimed is:
 1. A method of constructing a reinforced skateboarddeck comprising the steps of: providing a non-fiber-reinforced upperlayer and at least one non-fiber-reinforced lower layer; removing acentral portion of the upper layer to provide a central opening definedby a side barrier; providing a rupture resistant, fiber-reinforced layerto fit within the central opening of the side barrier; placing thefiber-reinforced layer within the central opening of the side barrier toform an exposed upper foot bearing surface defined by portions of thefiber-reinforced layer and the side barrier; and bonding the lower layertogether with the side barrier and the fiber-reinforced layer to form areinforced skateboard deck with a nose section, tail section, andintermediate section with opposing lateral edge sidewalls therebetweenwith at least a portion of the rupture resistant fiber-reinforced layerdisposed in the intermediate section.
 2. The method claim 1 furthercomprising the step of: saturating the fiber-reinforced layer inpolyurethane before the bonding step.
 3. The method of claim 1 furthercomprising the step of: die cutting the upper layer to form the centralopening.
 4. The method of claim 1 further comprising the step of:pressing the bonded layers together to form a skateboard deck having araised nose section and raised tail section.
 5. The method of claim 1further comprising the step of: inserting and bonding a spacer elementbetween the fiber-reinforced layer and an adjacent layer.
 6. The methodof claim 1 further comprising the step of: providing at least one morefiber-reinforced layer beneath the exposed fiber-reinforced foot bearingsurface.
 7. The method of claim 1 further comprising the step of:providing at least one additional layer between the foot bearing surfaceand an undersurface of the lower layer to fit within the central openingof the side barrier.
 8. The method of claim 1 further comprising thestep of: extending the central opening from the foot bearing surface toan undersurface of the lower layer.
 9. The method of claim 1 furthercomprising the step of: providing a plurality of rupture resistantlayers to fit within the central opening of the side barrier.
 10. Themethod of claim 9 further comprising the step of: spacing apart at leasttwo of the rupture resistant layers.
 11. The method of claim 1 furthercomprising the step of: forming discrete regions in the ruptureresistant layer within the central opening of the side barrier.
 12. Themethod of claim 1 further comprising the step of: bonding a secondaryrupture resistant, fiber-reinforced layer to the undersurface of thelower layer.
 13. The method of claim 1 further comprising the step of:bonding a secondary rupture resistant, fiber-reinforced layer within arecess formed in the undersurface of the lower layer.
 14. The method ofclaim 1 further comprising the step of: defining a lowermost truckmounting surface with spaced apart truck mounting regions on the lowerlayer.